Aircraft engine component with locally tailored materials

ABSTRACT

A method for making a component according to one embodiment of this disclosure includes modeling a response of the component to operating conditions. The model is then mapped to materials that would influence the response of the component to the operating conditions. A component is then fabricated using the materials such that the component includes a graded composition.

BACKGROUND

Aircraft components, such as the airfoils of the compressor and turbine sections of a gas turbine engine, are exposed to high temperatures and are subjected to large forces during operation of the engine. These airfoils are typically made from a single material, such as steel or nickel based alloys, that is selected to withstand the expected engine operating conditions. In another example, a component is formed in two halves, with each half being made of a different material. The two halves are then welded together to form a composite component.

SUMMARY

A method for making a component according to one embodiment of this disclosure includes modeling a response of the component to operating conditions. The model is then mapped to materials that would influence the response of the component to the operating conditions. A component is then fabricated using the materials such that the component includes a graded composition.

In a further non-limiting embodiment of the present disclosure, the model provides a response of the component at each of a plurality of regions of the component.

In a further non-limiting embodiment of the present disclosure, each of the plurality of regions of the component is mapped to a material that would influence the response of the component to the operating conditions.

In a further non-limiting embodiment of the present disclosure, the component is fabricated such that each of the plurality of regions of the component is fabricated using an respective one of the mapped materials.

In a further non-limiting embodiment of the present disclosure, the component is an airfoil of a gas turbine engine.

In a further non-limiting embodiment of the present disclosure, the component is fabricated using an additive manufacturing process.

In a further non-limiting embodiment of the present disclosure, the component is provided with a graded composition such that the component changes in composition in at least one direction.

In a further non-limiting embodiment of the present disclosure, the model is the result of a finite element analysis performed by a computing device.

In a further non-limiting embodiment of the present disclosure, the model indicates a thermal response of each of a plurality of regions of the component relative to the operating conditions.

In a further non-limiting embodiment of the present disclosure, each of the plurality of regions is mapped to a material that would influence the thermal response of the component relative to the operating conditions.

In a further non-limiting embodiment of the present disclosure, a region modeled to experience the highest temperature, relative to the remainder of the plurality of regions, is mapped to a material having the lowest thermal expansion coefficient, relative to the materials mapped to the remainder of the plurality of regions.

In a further non-limiting embodiment of the present disclosure, the model indicates stresses and strains experienced by each of a plurality of regions of the component relative to the operating conditions.

In a further non-limiting embodiment of the present disclosure, each of the plurality of regions is mapped to a material that would influence the strength of the component relative to the operating conditions.

In a further non-limiting embodiment of the present disclosure, the model indicates a vibratory signature of each of a plurality of regions of the component relative to the operating conditions.

In a further non-limiting embodiment of the present disclosure, each of the plurality of regions is mapped to a material that would influence the stiffness of the component relative to the operating conditions.

A component according to one non-limiting embodiment of this disclosure includes a composition graded according to a modeled response of the component to operating conditions. The composition includes a plurality of materials that influence the response of the component to the operating conditions.

In a further non-limiting embodiment of the present disclosure, the component is an airfoil.

In a further non-limiting embodiment of the present disclosure, the plurality of materials influences one of (1) a thermal response, (2) strength, and (3) stiffness, of the component relative to the operating conditions.

In a further non-limiting embodiment of the present disclosure, at least one of the plurality of materials includes a different chemical composition relative to at least one other of the plurality of materials.

In a further non-limiting embodiment of the present disclosure, the composition is graded such that the component changes in composition in at least one direction.

These and other features of the present disclosure can be best understood from the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings can be briefly described as follows:

FIG. 1 schematically illustrates a method according to one embodiment of this disclosure.

FIG. 2 illustrates an example modeled response of an aircraft component to operating conditions.

FIG. 3 illustrates an example process for forming an aircraft component.

FIG. 4 schematically illustrates an example additive manufacturing machine.

DETAILED DESCRIPTION

FIG. 1 illustrates an example method 10 for making an aircraft component, such as a component for a gas turbine engine of the aircraft. The method 10 includes modeling a response of an aircraft component to operating conditions, at 12. The response includes, but is not limited to, at least one of a thermal response, a vibratory response, and a stresses-and-strains response of the component to operating conditions. The model generated at 12 is then mapped, at 14, to materials that would influence the response of the aircraft component to the operating conditions. At 16, an aircraft component is fabricated with a graded composition corresponding to the mapped materials.

FIG. 2 illustrates an example of a modeled response of an aircraft component, here illustrated as an airfoil 18, to operating conditions. In this example, the airfoil 18 is an airfoil of the compressor or the turbine section of a gas turbine engine. While an airfoil 18 is illustrated, it should be understood that this disclosure is not limited to airfoils, and extends to other types of aircraft components, such as fan blades, stator vanes, and blade outer air seals (BOAS), as well as other components found within a gas turbine engine. While gas turbine engine components for an aircraft are specifically contemplated by this disclosure, this disclosure extends to components for other applications, including components used with industrial gas turbines, marine power plants and other portions of an aircraft (such as actuators and flaps for wings, etc.). This disclosure further extends to components for wind turbines.

With continued reference to FIG. 2, the airfoil 18 is exposed to a flow 20 during operating conditions. In the example, the flow 20 includes a core flow of the gas turbine engine. The operating conditions can further include rotations per minute (RPM) of the airfoil 18, and other such conditions that the airfoil 18 would be subjected to during operation. The operating conditions used to generate the model, at 12, can include expected operating conditions, actual operating conditions, and any other type of condition (such as a redline or failure condition) desired to be modeled. In other examples, where the aircraft component is not an airfoil, the operating conditions include the conditions experienced by such a component during operation of the associated gas turbine engine.

In FIG. 2, the model of the response of the airfoil 18 to the flow 20 is a thermal model, representing the temperatures the airfoil 18 is subjected to during operating conditions. In this example, the model generates a plurality of regions 22 a-22 f. Each of the regions 22 a-22 f corresponds to a temperature range experienced by a particular portion of the airfoil 18 during operating conditions. In another example, the model includes a model of the stresses and strains experienced by the airfoil 18 during the operating conditions. In yet another example, the model includes a vibratory signature of the airfoil during the operating conditions.

Based on the model, materials are mapped to the regions 22 a-22 f that would influence the response of the airfoil 18 to the operating conditions. For example, in FIG. 2, the model indicates that region 22 a, which generally corresponds to the leading edge of the airfoil 18, experiences the highest temperatures during operating conditions. Accordingly, the region 22 a is mapped to a material having a low thermal expansion coefficient relative to the remaining regions 22 b-22 f, for example.

Materials, such as steels, with low thermal expansion coefficients are known to be relatively expensive, and therefore it is not cost effective to make the entire airfoil 18 out of such a material. Instead, according to an example method 10 of this disclosure, the relatively cool regions 22 b-22 f of the airfoil 18 can be mapped to materials having relatively high thermal expansion coefficients when compared to region 22 a.

For example, the model generated at 12 indicates that region 22 b experiences a lower temperature than region 22 a during operating conditions, and thus is mapped to a material having a relatively higher thermal expansion coefficient than the material mapped to region 22 a. Similarly, region 22 c experiences a lower temperature than region 22 b and is thus mapped to a material having a relatively higher thermal expansion coefficient, and so on for the remaining regions. Each region 22 a-22 f may be mapped to a unique material relative to the remaining regions. In another example, certain regions, such as regions 22 b and 22 f, may be modeled to experience substantially the same temperature and are thus mapped to the same material.

As used herein, reference to “different” materials mapped to each of the regions 22 a-22 f should be understood to include materials having different chemical compositions. For example, the materials mapped to regions 22 a and 22 b could both be steel or alloys, although they can have different chemical compositions. Further, while steel is mentioned herein, this application is not limited to steel. Instead, other materials, such as other metals, plastics, or ceramics, can be used herein.

In examples where the model does not model temperature, but models some other response of the aircraft component to the operating conditions, the materials mapped to the regions in the model can be selected to influence the aircraft component in some other appropriate manner. For example, when the stresses and strains of the aircraft component are modeled, the model is mapped to materials that would influence the strength of the aircraft component. In this case, the result of the model may indicate that denser materials may be needed near the axis of rotation of the aircraft component Likewise, when a vibratory signature is modeled, the model is mapped to materials that would influence the stiffness of the aircraft component.

In a further example of this disclosure, the modeled response is performed, at 12, using a computing device. The computing device in this example is a known type of computer including hardware, such as a hard drive and a processor, and is capable of running software. The software in one example is a finite element analysis (FEA) program capable of modeling a response of a particular component to certain input conditions, which here would be the operating conditions of the engine (including exposure of the airfoil 18 to the flow 20). The step of mapping materials, at 14, is further performed by the computing device in this example. To perform this step, the computing device includes, or has access to, a database of materials and is configured to select certain materials based on cost and performance constraints, or other constraints.

In still a further example of this disclosure, a plurality of different models (e.g., a first model could indicate a thermal response, and a second model could indicate the vibratory signature) could be considered when mapping the materials to specific regions. For example, the aircraft component 18 could be modeled such that region 22 a experiences a relatively high temperature and relatively low vibration, compared to the remainder of the airfoil 18, during operating conditions. Thus, the region 22 a would be mapped to a material exhibiting a low thermal coefficient and a low stiffness relative to the remainder of the airfoil. Additionally, a weighting system could be used when mapping materials to the particular regions of the component, if desired, to account for relative importance of the particular models.

Accordingly, this method can be used to provide an aircraft component with locally tailored materials such that the materials are provided in regions where they are most needed, thus using these materials in a cost effective manner.

Once the materials are mapped to the regions generated using the model, at 14, the aircraft component is fabricated with a graded composition corresponding to the mapped materials. One method specifically contemplated by this disclosure includes additive manufacturing, although other fabricating methods may be used. Additive manufacturing techniques enable one to fabricate a single component out of a plurality of different materials, and can be used to provide the component with a graded composition. Graded components change in composition in a particular direction, for example in the direction of the length or width of the component.

An example additive manufacturing process 24 is illustrated in FIG. 3. In the example process 24, powdered metal 26 used for forming the aircraft component is provided within a machine 28. With reference to the computer aided drafting (CAD) data 30, which the aircraft component is produced at 32, by building up layers of fused powdered metal. As the machine 28 builds the aircraft component, the machine 28 can be provided with different materials, to correspond to the mapped materials from 14. In this example, the CAD data 30 represents a particular component design, and includes instructions for adding a particular material into the machine 28 at a particular stage in the machining process.

FIG. 4 schematically illustrates an example additive manufacturing machine 28. In the example, a powdered metal 26 is provided on a bed 34 and is fused by an additive manufacturing process. As illustrated, the additive manufacturing process is an energy beam fusing process, including an energy beam source 36 which generates an energy beam 38. The energy beam could be one of an electron beam and a laser beam.

As mentioned above, the bed 34 can be provided with different powdered metals 26, depending upon the material desired for a particular region of the aircraft component. Multiple beds may be alternatively used with each bed 34 for a different powdered metal. In this respect, a desired metal powder is added, as schematically shown at 40, to the bed 34. When that particular metal is no longer needed, the excess powder 42 is removed from the bed 34, as represented at 42, and a new powdered metal of a different composition is added.

Again, while powdered metal is specifically mentioned relative to the additive manufacturing process, this disclosure extends to other types of materials, such as ceramics and polymers.

Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.

One of ordinary skill in this art would understand that the above-described embodiments are exemplary and non-limiting. That is, modifications of this disclosure would come within the scope of the claims. Accordingly, the following claims should be studied to determine their true scope and content. 

What is claimed is:
 1. A method for making a component, comprising: modeling a response of a component to operating conditions; mapping the model to materials that would influence the response of the component to the operating conditions; and fabricating a component using the mapped materials, the component provided with a graded composition.
 2. The method as recited in claim 1, wherein the model provides a response of the component at each of a plurality of regions of the component.
 3. The method as recited in claim 2, wherein each of the plurality of regions of the component is mapped to a material that would influence the response of the component to the operating conditions.
 4. The method as recited in claim 3, wherein the component is fabricated such that each of the plurality of regions of the component is fabricated using a respective one of the mapped materials.
 5. The method as recited in claim 1, wherein the component is an airfoil of a gas turbine engine.
 6. The method as recited in claim 1, wherein the component is fabricated using an additive manufacturing process.
 7. The method as recited in claim 1, wherein the component is provided with a graded composition such that the component changes in composition in at least one direction.
 8. The method as recited in claim 1, wherein the model is the result of a finite element analysis performed by a computing device.
 9. The method as recited in claim 1, wherein the model indicates a thermal response of each of a plurality of regions of the component relative to the operating conditions.
 10. The method as recited in claim 9, wherein each of the plurality of regions is mapped to a material that would influence the thermal response of the component relative to the operating conditions.
 11. The method as recited in claim 10, wherein a region modeled to experience the highest temperature, relative to the remainder of the plurality of regions, is mapped to a material having the lowest thermal expansion coefficient, relative to the materials mapped to the remainder of the plurality of regions.
 12. The method as recited in claim 1, wherein the model indicates stresses and strains experienced by each of a plurality of regions of the component relative to the operating conditions.
 13. The method as recited in claim 12, wherein each of the plurality of regions is mapped to a material that would influence the strength of the component relative to the operating conditions.
 14. The method as recited in claim 1, wherein the model indicates a vibratory signature of each of a plurality of regions of the component relative to the operating conditions.
 15. The method as recited in claim 14, wherein each of the plurality of regions is mapped to a material that would influence the stiffness of the component relative to the operating conditions.
 16. A component, comprising: a composition graded according to a modeled response of the component to operating conditions, the composition including a plurality of materials that influence the response of the component to the operating conditions.
 17. The component as recited in claim 16, wherein the component is an airfoil.
 18. The component as recited in claim 16, wherein the plurality of materials influences one of (1) a thermal response, (2) strength, and (3) stiffness, of the component relative to the operating conditions.
 19. The component as recited in claim 16, wherein at least one of the plurality of materials includes a different chemical composition relative to at least one other of the plurality of materials.
 20. The component as recited in claim 16, wherein the composition is graded such that the component changes in composition in at least one direction. 